Conveyor chain

ABSTRACT

A conveyor chain includes a plurality of side link assemblies and flight arm assemblies coupled together to form an elongated chain. The flight arm assemblies include a pair of opposing flight arms positioned on either side of the chain with the flight arms each including an elongated body formed with and extending from an integral base and a vertical sprocket opening formed in the integral base. The vertical sprocket opening is configured for engaging a tooth of a drive sprocket to drive the flight arm. The side link assemblies include a pair of opposing side straps positioned on either side of the chain each including a base and a pair of side strap bosses extending outwardly from the base. An articulating connector is positioned between a flight arm assembly and a side link assembly to couple the assemblies together and includes a solid piece and side surfaces having profiled surfaces therein and configured for receiving at least one of a portion of a side strap of a side link assembly or a portion of a base of a flight arm assembly for providing articulation of the assemblies.

PRIORITY

This application is a continuation-in-part application of U.S. patentapplication Ser. No. 14/445,981, entitled “CONVEYOR CHAIN”, filed Jul.29, 2014; which application is a continuation-in-part application ofU.S. patent application Ser. No. 13/908,343, entitled “CONVEYOR CHAIN”,filed Jun. 3, 2013; which application is a continuation-in-partapplication of U.S. patent application Ser. No. 12/559,799, entitled“CONVEYOR CHAIN”, filed Sep. 15, 2009, now Issued U.S. Pat. No.8,453,826, issued Jun. 4, 2013; which application claims priority toU.S. Provisional Patent Application Ser. No. 61/098,870, filed Sep. 22,2008, entitled “CONVEYOR CHAIN,” and U.S. Provisional Patent ApplicationSer. No. 61/234,398, filed Aug. 17, 2009, entitled “CONVEYOR CHAIN,” theapplications, patent, and disclosures of which are incorporated byreference herein in their entireties.

BACKGROUND

Pusher-type chain conveyors, as used in the mining industry, are foundboth in the form of separate conveying units, and as integral parts ofcontinuous mining machines. One example of a continuous mining machineis a self-propelled mining machine. It is provided at its forward endwith cutting means shiftable in such a way that an entry is cut in thematerial being mined. The entry is so sized as to permit passage of themining machine therethrough. Since the cutting operation is a continuousone, it is advantageous to provide means to move the cut material fromin front of the mining machine and to convey it out of the entry.

One or several conveyors may be incorporated into the mining machine'sconstruction that acts successively to transport the cut materialrearwardly from the machine. One example of a conveyor that isincorporated into the mining machine extends from the front to the rearof the machine. The purpose of this conveyor is to remove the cutmaterial from entry and deliver the cut material to other conveyingmeans. The other conveying means may comprise mine cars or othervehicles used for hauling, portable belt conveyors or other conveyorsdesigned for loading and unloading mined material from the miningmachine, or the like.

An example of a conveyor that has been encountered in association with acontinuous mining machine includes a section of conveyor base meansmounted on the mining machine body. One or more additional sections ofconveyor base means are connected thereto end-to-end, and extend beyondthe rearward end of the mining machine body. All of the base meanssections are characterized by a bottom portion provided withlongitudinally extending, upstanding side guides or flanges. The varioussections of the tail conveyor can be capable of both lateral andvertical movement with respect to each other, which enables the cutmaterial to be delivered to a desired point despite changes of positionof the mining machine as it advances in the entry and changes in levelof the entry floor. The lateral and vertical movement capability of theconveyor sections may also enable the shifting of the desired deliverypoint for the material being mined, as required.

This type of conveyor may incorporate a continuous pusher-type conveyorchain, which is driven along the length of the conveyor base sections.The chain may be provided with a plurality of rigid pusher elements,normally extending substantially transversely of the conveyingdirection. The pusher elements are located at spaced intervals along thechain. Adjacent pusher elements may be joined together by a series ofalternate block-like links and plate-like links. At one end of themachine's conveyor, the continuous chain passes over a driven sprocket.At the other end of the conveyor, the chain passes over a driven oridler sprocket, or roller.

Various embodiments of a conveyor chain configured to be used inconjunction with a dual drive sprocket on a mining machine are disclosedin the following applications: U.S. Provisional Patent Application No.60/238,877, filed Oct. 6, 2000; PCT Patent Application Serial No.PCT/US01/31746, filed Oct. 9, 2001; and U.S. Nonprovisional patentapplication Ser. No. 10/398,387, which was filed on Apr. 7, 2003 and isnow issued as U.S. Pat. No. 8,016,102; the disclosures of which areincorporated by reference herein.

Typically in the underground mining industry, machine downtime is veryexpensive. Should a conveyor chain fail (due to sudden impact or wear),the chain often would come apart during production causing several hoursof expensive and unproductive downtime while the chain was repaired.Most often a conveyor chain fails from impact loads on the flight armsor other parts of the chain.

Accordingly, it is desirable to provide a conveyor chain that hasspecific features and structures to provide a robust design whichfunctions as desired, are quiet, and will not fail under rigorous usage.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate speech recognition systemcomponents and embodiments of the invention and, together with thedetailed description of the embodiments given below, serve to explainthe principles of the invention.

FIG. 1 is a plan view of a typical continuous mining machine having atail conveyor for initializing the chain of the invention.

FIG. 2 depicts a perspective view of a segment of an exemplary conveyorchain in accordance with an embodiment of the invention.

FIG. 3 depicts a perspective view of an exemplary side strap of anembodiment of the invention.

FIG. 4 depicts a perspective view of an exemplary connecting pin of anembodiment of the invention.

FIG. 5 depicts a perspective view of an exemplary universal link of anembodiment of the invention.

FIG. 5A is a top view of an exemplary universal link of an embodiment ofthe invention.

FIG. 5B is a side view of the exemplary universal link of FIG. 5A.

FIG. 6 depicts a perspective view of an exemplary connector link of anembodiment of the invention.

FIG. 6A is a top view of an exemplary connector link of an embodiment ofthe invention.

FIG. 6B is a side view of the exemplary connector link of FIG. 6A.

FIG. 7 depicts a perspective view of an exemplary universal connectorassembly of an embodiment of the invention.

FIG. 8 depicts a side cross-sectional view of the exemplary universalconnector assembly of FIG. 7 of an embodiment of the invention.

FIG. 9 depicts a top plan view of an exemplary flight arm of anembodiment of the invention.

FIG. 10 depicts a side elevation view of the exemplary flight arm ofFIG. 9 of an embodiment of the invention.

FIG. 11 depicts an end view of the exemplary flight arm of FIG. 9 of anembodiment of the invention.

FIG. 12 depicts a perspective view of an exemplary flight pin of anembodiment of the invention.

FIG. 13 depicts a perspective view of a section of exemplary conveyorchain engaged with an exemplary driving member comprising a dual drivesprocket of an embodiment of the invention.

FIG. 14 depicts a perspective view of a section of exemplary conveyorchain engaged with an exemplary driving member comprising a triple drivesprocket of an embodiment of the invention.

FIG. 15A is an exploded perspective view of an exemplary side linkassembly of an embodiment of the invention.

FIG. 15B is a side view of the exemplary side link assembly of FIG. 15A.

FIG. 16 is an exploded perspective view of an exemplary side linkassembly of an embodiment of the invention.

FIG. 17 is a perspective view of a segment of an exemplary conveyorchain in accordance with an embodiment of the invention.

FIG. 18 is a perspective view of a segment of an exemplary conveyorchain in accordance with another embodiment of the invention.

FIG. 19 is another perspective view of a portion of the exemplaryconveyor chain illustrated in FIG. 18.

FIG. 20 is an exploded perspective view of a portion of the exemplaryconveyor chain illustrated in FIG. 19.

FIG. 21 is a top cross-sectional view of the solid articulatingconnector of FIG. 22 in accordance with one embodiment of the invention.

FIG. 22 is a side view of the solid articulating connector of FIG. 20 toprovide articulation in a conveyor chain.

FIG. 23 is a top perspective view of another embodiment of a solidarticulating connector in accordance with the invention.

FIG. 24 is a perspective view of a segment of another exemplary conveyorchain in accordance with an embodiment of the invention.

FIG. 25 is a top perspective view of another embodiment of a solidarticulating connector of the invention.

FIG. 26 is a perspective view of a segment of another exemplary chain,in accordance with an embodiment of the invention.

FIG. 27 is a perspective view of a segment of another exemplary conveyorchain in accordance with an embodiment of the invention.

FIG. 28 is a perspective view of a segment of an exemplary conveyorchain in accordance with another embodiment of the invention.

FIG. 29 is a perspective view of another embodiment of a solidarticulating connector in accordance with the invention.

FIG. 30 is a top cross-sectional view of the solid articulatingconnector of FIG. 29 in accordance with one embodiment of the invention.

FIG. 31 is a side view of the solid articulating connector of FIG. 29 toprovide articulation in a conveyor chain.

FIG. 32 is another perspective view of a portion of the exemplaryconveyor chain illustrated in FIG. 28.

FIG. 33 is an exploded perspective view of a portion of the exemplaryconveyor chain illustrated in FIG. 32.

FIG. 34 is an end view of the solid articulating connector of FIG. 29 toprovide articulation in a conveyor chain.

FIG. 35 is a top cross-sectional view of the solid articulatingconnector of FIG. 29 in accordance with one embodiment of the invention

The drawings are not intended to be limiting in any way, and it iscontemplated that various embodiments of the invention may be carriedout in a variety of other ways, including those not necessarily depictedin the drawings. The accompanying drawings incorporated in and forming apart of the specification illustrate several aspects of the presentinvention, and together with the description serve to explain theprinciples of the invention; it being understood, however, that thisinvention is not limited to the precise arrangements shown.

DETAILED DESCRIPTION

The following description of certain examples of the invention shouldnot be used to limit the scope of the present invention. Other examples,features, aspects, embodiments, and advantages of the invention willbecome apparent to those skilled in the art from the followingdescription, which is by way of illustration, one of the best modescontemplated for carrying out the invention. As will be realized, theinvention is capable of other different and obvious aspects, all withoutdeparting from the invention. Accordingly, the drawings and descriptionsshould be regarded as illustrative in nature and not restrictive.

For better understanding of the invention, reference is first made toFIG. 1, illustrating an exemplary environment for the chains of thepresent invention. FIG. 1 diagrammatically illustrates a typicalcontinuous mining machine generally indicated at 2 and provided with atail conveyor, generally indicated at 3. The mining machine has a bodyportion 4 which is usually mounted on wheels or treads and isself-propelled. At the forward end of the mining machine, cuttingelements are provided as shown at 5 and 6. These cutting elements 5 and6 may take various well known forms and are suitably mounted such as onthe frame 7, enabling the cutting means to be shifted in such a way thatthey will cut an entry large enough to receive and to permit advancementof the mining machine 2 in the cutting direction indicated by arrow A.

By various well-known conveying means, the cut material at the forwardend of the mining machine is gathered and transported over or throughthe mining machine to the tail conveyor 3. This last mentioned conveyorcomprises a conveyor base element, illustrated in FIG. 1 as made up oftwo sections 8 and 9. The base element section 8 has a bottom portion 10and upstanding side guide or flanges 11 and 12. Similarly, the section 9has a bottom portion 13 and upstanding side guides or flanges 14 and 15.The section 9 is mounted on a boom 16 articulated to the rearward end ofthe mining machine body 4 as at point 17. The articulation is such thatthe boom 16 and its conveyor base element section 9 are shiftable withrespect to the conveyor base element section 8 both in the verticalplane and the horizontal plane. A pusher-type conveyor chain, generallyindicated at 18, extends along the length of the conveyor base elementsections 8 and 9 and is adapted to be driven along the upper surface oftheir bottom portions 10 and 13. It will be understood that the chain 18is a continuous chain. Normally it will be driven by a sprocketpositioned at least at one end of the tail conveyor 3.

As shown in FIG. 1, a typical chain 18 is provided with a plurality ofspaced pusher elements arms 19, extending substantially transversely ofthe conveying direction indicated by arrow B. It will be seen that thepusher elements preferably extend to both side if the chain 18 and thatthe pusher elements are located at predetermined intervals along thelength of the chain.

FIG. 2 illustrates a section of a conveyor chain 25 for use in a devicesuch as that illustrated in FIG. 1. The chain section illustrated inFIG. 2 comprises two side link assemblies 35, four connector assemblies40, and two flight arm assemblies 50. Of course, conveyor chain 25 willcomprise any suitable number of side link assemblies, connectorassemblies, and flight assemblies to produce a chain of sufficientlength for a particular application. It will be appreciated that thereis some appropriate duplication in the link assemblies. For example,side strap 33 may be virtually identical to side strap 34 in the sidelink assembly. In the illustrated embodiment, each universal connectorassembly 40 comprises a universal link 42 FIG. 5 and a connector link 43FIG. 6 with a universal pin 41 FIG. 7 extending through the universallink 42 and the connector link 43. As shown in FIG. 2, each flight armassembly 50 comprises a pair of flight arm pins 51, 52 and a pair offlight arms 53, 54.

In the illustrated embodiment, the two side straps 33, 34 of each sidelink assembly 30 are spaced apart and positioned so that the two sidestrap bosses 37, 38 are facing outwardly with respect to a center lineof the chain. In this example, each side strap boss 37, 38 comprises ahollow circular protrusion that includes an opening 39 that extendsthrough the side strap boss 37, 38 and through base 35. Each side strapboss 37, 38 is configured to receive at least a portion of a connectingpin 31, 32. The connecting pins span between the side straps and connectthe opposing side straps. Of course, side strap bosses 37, 38 maycomprise any suitable shape, including but not limited to circular andsquare.

As shown in FIGS. 13 and 14, when the chain is driven, the side strapbosses 37, 38 are configured to engage a tooth 112 of a sprocket, suchas one of sprockets 114 a, 114 b of drive mechanism 100 or outersprockets 214 a, 214 b of drive mechanism 200. The chain is engaged anddriven by a suitable driving member, such as a dual drive sprocket 100FIG. 13, a triple drive sprocket 200 FIG. 14 or any other suitabledriving member. The chain of the present invention is configured to beable to handle both a dual drive sprocket arrangement, as illustrated inFIG. 13, or a triple drive sprocket arrangement as in FIG. 14 dependingon its use. In the illustrated embodiments, the side strap 33 in eachside link assembly 30 is aligned with side strap 34 such that each sidestrap boss 37, 38 of side strap 33 is aligned with a corresponding sidestrap boss 37, 38 of side strap 34. In the embodiments, a firstconnecting pin 31 is inserted through the aligned side strap bosses 37in side straps 33, 34, while a second connecting pin 32 is insertedthrough the aligned side strap bosses 38 in side straps 33, 34.Collectively, the side straps 33, 34 and connecting pins 31, 32 form aside link assembly 30.

The diameter of the connecting pins 31, 32 may be about 1⅛ inch, or anyother suitable dimension. By way of example only, in some embodimentsthe diameter of the connecting pin 31, 32 may range from about 1 inch toabout 1¼ inch. Increasing the diameter of the connecting pins 31, 32compared to bearing pins used in existing conveyor chains will improvethe strength and reliability of the conveyor chain during operationwhile reducing the chance of chain breakage. The connecting pins 31, 32and side strap bosses 37, 38 may be configured to provide a press fit, asliding close tolerance fit, or any other suitable fit between thecomponents to form the complete side link assembly. Connecting pins 31,32 may be retained within side strap bosses 37, 38 by keeper pins,retaining rings, by press fit alone, or by any other suitable method ordevice. In one embodiment a ring is press fit onto the end of theconnecting pin to engage groove 21 and hold the pins in the side straps33, 34 of the side link assemblies (see FIG. 4).

While the embodiment of the invention is illustrated in FIG. 2 showsconnecting pins 31, 32 that are retained within the side strap bosses47, 48 by a press fit ring and a ring 23, FIGS. 15A, 15B and 16illustrate alternative embodiments to the invention wherein alternativesecuring elements are utilized with the connecting pins, 31, 32 forforming the side link assembly 30. Specifically, as illustrated in FIG.15A, the connecting pins 31, 32 are inserted into the corresponding andaligning side strap bosses 37, 38 of the opposing side straps 33, 34.The connecting pins 31, 32 include connector grooves 21 formed thereinat each end. When the connecting pins 31, 32 extend through the sidestrap bosses 37, 38, the corresponding grooves 21 at either end of theconnecting pins are exposed adjacent the end of the respective bosses37, 38. Retaining rings 80 in the form of external retaining areexpandable rings that may be expanded or spread apart, are appropriatelypositioned around an end of the connecting pins 31, 32 and are thendimensioned in an unexpanded state to engage the grooves 21 and fitsnuggly against the ends of the bosses 37, 38 to secure the connectingpins in the side straps 33, 34. The retaining rings 80 are illustratedin FIGS. 15A and 15B on one side of the assembly 30, but it will bereadily understood that the retaining rings are implemented on both endsof the connecting pins 31, 32 for holding the pins in each of the sidestraps 33, 34. The external retaining rings or snap rings 80 may beformed with a suitably strong material such as stainless steel and mayhave an inner diameter around 1 1/16 inches. FIG. 15B illustrates a sideview of side link assembly 30 with rings 80 in place with the connectingpins 31, 32.

Turning now to FIG. 16, that figure illustrates a side link assembly 30and incorporates other retaining elements. Specifically, one or morespiral retaining rings 82 are utilized to fit into the grooves 21 ofconnecting pins 31, 32. The spiral retaining ring may be single turn ormulti-turn spiral retaining rings. As illustrated in FIG. 16, multiplespiral rings might be utilized to hold the connecting pins 31, 32.Alternatively, only a single spiral retaining ring might be utilized inthe embodiment as shown in FIG. 16. The external retaining rings 80 andspiral retaining rings 82 provide for an easier disassembly of the sidelink assembly such as for replacement or repair. The rings, 80, 82 maybe removed and re-installed numerous times without destroying the ringsor weakening their engagement with the pins.

FIGS. 5-8 depict one embodiment of a universal connector assembly 40. Inthe illustrated embodiment, universal connector assembly 40 comprises auniversal pin 41, a universal link 42, and a connector link 43. Theuniversal link 42 as pictured in FIG. 5, comprises an upper lip 61 andlower lip 62 each having a vertical thru-hole 63, 64 that is configuredto receive at least a portion of the universal pin 41. The universallink 42 can also be described as the female link. In this example,universal link 42 further comprises connecting portion 65 that extendsbetween upper lip 61 and lower lip 62. As shown, connecting portion 65is rounded and has an inside surface that forms a horizontalbore/thru-hole 67 configured to receive at least a portion of aconnecting pin 31, 32 of a side link assembly or a flight pin 51, 52 ofa flight arm assembly. The universal link 42 also includes a groove 45formed on the outside surface of the connecting portion 65. The groove45 of universal connector assembly 40 provides a surface for engagementby a center or third sprocket for driving the chain discussed herein. Inthe illustrated embodiment, connector link 43 comprises a projectingmember 71 sized and shaped to fit between the upper lip 61 and lower lip62 of the universal link 42 as shown in FIG. 7. The connector link 43can also be described as a male link. In this version, projecting member71 includes a vertical bore or thru-hole 72 that is configured toreceive a universal pin 41. In this example, connector link 43 furthercomprises a horizontal bore or opening 73 that extends through the widthof connector link 43 and is configured to receive at least a portion ofa connecting pin 31, 32 or a flight pin 51, 52. The connector link 43also includes a groove 47 formed on an end of the connector linkopposite the projecting member. Groove 47 also provides a surface forengagement by a center/third sprocket for driving the chain if desired.

As shown in FIGS. 7 and 8, when universal connector assembly 40 is fullyassembled, the projecting member 71 of the connector link 43 is insertedbetween the upper lip 61 and lower lip 62 of the universal link 42. Inthis example, vertical thru-holes 63, 64 of the universal link 42 areaxially aligned with vertical thru-hole 72 of the connector link, suchthat the universal pin 41 may pass through the vertical thru-holes 64,63, 72 as shown in FIGS. 7 and 8. The universal pin 41 may be configuredto increase mobility of the chain, allow the chain to articulate pastobjects, and reduce the load transmitted to the connecting pins 31, 32when an obstruction in a conveying deck is encountered. FIGS. 5A-5B and6A-6B illustrate alternative universal links and connector linksrespectively in accordance with another embodiment of the invention.Specifically, the universal link 42 a and connector link 43 a includethru-holes or bores that are induction hardened to have a greaterhardness than the remaining portions of the respective links. Forexample, referring to FIGS. 5A and 5B, the horizontal bore or thru-hole67 is hardened at a specific depth around the bore to a greater hardnessrating than the rest of the link. For example, while the universal link42 a, after machining, might have a hardness of around 40-44 on theRockwell C Scale (40-44 Rc) the thru-hole bore 67 might be inductionhardened to have a hardness rating of around 50-54 Rc. In accordancewith one embodiment of the invention, such hardness may be induced to adepth D of ⅛ inch to 3/16 inches deep around the thru-hole andcompletely through that hole 67.

Connector link 43 a as shown in FIGS. 6A-6B might also be hardened inaccordance with an embodiment of the invention. To that end, verticalbore or thru-hole 72 and horizontal bore or opening 73 might also behardened to a hardness of 50-54 Rc around the bore or hole to a depth Dof ⅛ inch to 3/16 inches.

In accordance with an aspect of the invention, the localized bore orthru-hole hardening in the links, 42 a, 43 a of a universal connectorassembly with respect to the overall link elements will reduce the wearin those various high bore and wear areas where the pins 41 and 31, 32,51, 52 engage and thus extend the overall life of the chain. Generally,a universal pin 41, as illustrated in FIG. 7, is held in place in holes63, 64, such as by a weld 49. Therefore the hardening of hole 72provides desirable wear resistance. Similarly, as the hole 67 andopening 73 rotate around connecting pins 31, 32 or flight pins 51, 52,the hardening of those holes and openings provide additional wearresistance to extend the overall life of the chain.

When the various elements of the universal connector assembly arehardened, they are induction hardened by positioning a coil in thevarious holes or bores introducing significant heat, such as around1600° Fahrenheit to that coil. The temperature and length of time of theinduction hardening may be adjusted accordingly in order to achieve thedesired depth of induction hardening of the noted bores and thru-holes.

As shown in FIG. 2, flight arm assembly 50 comprises a pair of flightpins 51, 52 and a pair of flight arms 53, 54 positioned on either sideof the chain. In the example of FIGS. 9-11, each flight arm 53, 54comprises an elongated body 55 extending substantially perpendicularfrom an integral base 56. In this embodiment, each base 56 includes apair of flight arm attachment apertures 57, 58 or pockets that extendtransversely through the base 56. Each flight arm attachment aperture57, 58 may be configured to receive at least a portion of one of theflight pins 51, 52. As shown, each base 56 further comprises a verticalsprocket opening 59 that is formed through the base and extendsvertically through the base 56. The diameter of the flight pin may beabout 1⅛ inch, or any other suitable dimension. By way of example only,in some embodiments the diameter of the flight pin 51, 52 may range fromabout 1 inch to about 1-% inch. Increasing the diameter of the flightpins 51, 52 compared to bearing pins used in existing conveyor chainswill improve the strength and reliability of the conveyor chain duringoperation while reducing the chance of chain breakage. The flight pins51, 52 and bases 56 may be configured to provide a press fit, a slidingclose tolerance fit, or any other suitable fit between the components.Flight pins 51, 52 may be retained within the flight arm attachmentapertures 57, 58 of bases 56 by keeper pins, welding by press fit, bypress fit and weld, or by any other suitable method or device.

As shown in FIGS. 9-11, flight arm 53, 54 comprises an elongated body 55having a flat, planar bottom surface 111 and an integral base 56. Inthis version, elongated body 55 comprises a central rib 101 that may actas a pusher for the material being conveyed. In this example, the outerfree end of flight arm 53, 54 is provided with a knob-like portion 102which can ride against side guide elements associated with theconveyors. The base 56 may be provided with a vertical sprocket opening59. As shown in FIGS. 13 and 14, sprocket opening 59 is sized and shapedto engage a tooth 112 of a drive sprocket such as one of sprockets 114a, 114 b of driving member 100 or sprockets 214 a, 214 b of drivingmember 200 when the chain is engaged and driven by a suitable drivingmember, such as a dual drive sprocket 100, a triple drive sprocket 200or any other suitable driving member. While sprocket opening 59 issubstantially rectangular in the illustrated embodiment, it will beappreciated that sprocket opening 59 may comprise any suitable shapeconfigured to receive and engage a tooth 112, including but not limitedto circular, oval, square, and rectangular. The base 56 also has agroove 61 formed in the base 56 along a bottom of the base for properengagement and clearance of any sprocket teeth 102. In the illustratedversion, base 56 also comprises the two flight arm attachment aperture57, 58. As shown in FIG. 2, flight arm 53 in each flight arm assembly 50is aligned with flight arm 54 on the other side of the chain such thatthe flight arm attachment apertures 57, 58 of flight arm 53 are alignedwith the flight arm attachment apertures 57, 58 of flight arm 54. Inthis example, a first flight pin 51 is inserted through the alignedflight arm attachment apertures 57 in flight arms 53, 54, while a secondflight pin 52 is inserted through the aligned flight arm attachmentapertures 58 in the flight arms 53, 54. In addition, each of the flightpins 51, 52 are inserted through appropriate horizontal openings 73 of apair of connector links 43 or holes 67 a pair of universal linkspositioned between the flight arms 53, 54.

As shown in FIG. 2, section of conveyor chain 25 comprises a pluralityof alternating side link assemblies 30 and flight arm assemblies 50connected by connector assemblies 40. In this version, each universalconnector assembly 40 is configured and arranged to be connected to botha side link assembly 30 and a flight arm assembly 50. In this example,conveyor chain 25 comprises a side link assembly 30 connected to a firstuniversal connector assembly 40, a flight arm assembly 50 connected toboth the first universal connector assembly 40 and a second universalconnector assembly 40, and the second universal connector assembly 40 isconnected to a second side link assembly 30 and so on in a repeatingpattern. While the illustrated version depicts a chain comprisingalternating side strap assemblies 30 and flight arm assemblies 50, itwill be appreciated that a section of chain may comprise any suitablearrangement of side strap assemblies 30 and flight arm assemblies 50. Byway of example only, in an alternate embodiment (not shown), a sectionof conveyor chain may comprise two side strap assemblies positionedbetween a pair of flight arm assemblies. As shown in FIG. 2, a side linkassembly 30 is connected to a universal connector assembly 40 via aconnecting pin 32. In this version, connecting pin 32 is positioned suchthat it passes through the aligned side strap bosses 38 of side straps33, 34 and the opening 67 formed by connecting member 65 of universallink 42. (Alternatively, a side link assembly 30 may be connected to auniversal connector assembly 40 via a connecting pin 31 such thatconnecting pin 31 is positioned so that it passes through the alignedside strap bosses 37 of side straps 33, 34 and the horizontal opening 73in connector link 43.) Similarly, flight assembly 50 may be connected toa universal connector assembly 40 by positioning a flight pin 51, 52through a pair of aligned flight arm attachment apertures 57, 58 in twoopposing flight arms 53, 54 and the horizontal opening 73 in connectorlink 43. (Alternatively, a flight assembly 50 may be connected to auniversal connector assembly 40 by positioning a flight pin 51, 52through a pair of aligned flight arm attachment apertures 57, 58 in twoopposing flight arms 53, 54 and the opening 67 formed by connectingmember 65 in a universal link 42.)

FIG. 17 illustrates another embodiment of the invention. Chain 250 issimilar to the chains described herein in many details but alsoincorporates flight assemblies having an alternative construction.Specifically, chain 250 incorporates flight arm assemblies 260 thatincorporate flight arms that are covered in a suitable urethane material270. The urethane material, in accordance with one aspect of theinvention, provides for a reduction in the noise generated when thechain 250 is in operation. While chain 250, incorporates differentflight arm assemblies 260, other components of the chain, such as theside link assemblies and universal connector assemblies may beconstructed as noted herein. Each of the flight arm assemblies 260includes a pair of flight pins 51, 52 as discussed above. Each of theflight arms 262 also includes an elongated body 264 which extendssubstantially perpendicular from an integral base 266. Base 266 mayresemble base 56 illustrated in other figures and discussed herein. Thatis, the base includes a pair of flight arm attachment apertures 57, 58that extend transversely through the base. Each base also includes avertical sprocket opening 59 that is formed through the base and extendsvertically therethrough, such as to receive the teeth of drivesprockets.

Each flight assembly 260 includes a layer of urethane material 270 thatis formed or appropriately applied to the elongated body 262 of theflight arms. The elongated body 262 incorporates a series of aperturesthat are formed in the body 262. The embodiment illustrated in FIG. 17shows 5 apertures, including apertures 272 having a circular diameter of1.25 inches and two larger apertures 274 having a circular diameter ofapproximately 2 inches. The apertures are formed through each of theflight arms from top to bottom and provide passages for the flow ofurethane material therethrough to form an integral attachment of theurethane material layer 270 to the flight arm bodies 262. For example,the urethane material may be flowed or formed over the flight arm bodies262 in a liquid or semi liquid form which flows or extends through theapertures 272, 274. The urethane material then hardens and secures thematerial layer 270 to the flight arm 262 to become an integral part ofthe flight assembly 260. The urethane material layer is illustrated overmost or all of the elongated body of the flight arm, but urethanematerial might be used over at least a portion of the elongated body. Itwould be understood by person of ordinary skill in the art thatapertures having a shape or cross section that is different than acircular cross section may be implemented. Furthermore, a greater orlesser number of apertures may be utilized along the length of theflight arm bodies 262. Still further, different sizes of apertures maybe implemented along the length of the flight arm bodies 262, thereforethe invention is not limited to the number, size or shape of theapertures formed in the flight arm as illustrated in the example of theFigures. Each flight arm body 262 has a generally flat upper surface 276and lower surface 278. Similarly, the urethane material layer 270 in theembodiment illustrated in FIG. 17, is shown to have a similar flatupper, lower surface conforming with the surfaces 276, 278 of the flightarm bodies 262. In that way, the flight arm slides freely along aconveyor surface. Also, although the urethane material layer 270illustrated in FIG. 17 is shown to be somewhat clear, thus revealing theelongated the flight arm bodies 262, urethane material 270 might also beopaque in order to hide the internal flight arm body 262.

In another alternative embodiment of the invention, elements of thechain are covered with a corrosion protective coating. For example, theelements might be galvanized, or maybe covered with a nickel coating. Inone embodiment, various connecting pins 31, 32 and flight pins 51, 52 aswell as the universal pin 41, universal link 42 and connector link 43are all coated as appropriate for protection against corrosion.Additionally, the elements of the side link assembly, including the base35 and side strap bosses 37, 38 and any internal openings 39 may becoated with a suitable corrosion protective coating.

As shown in FIG. 13, conveyor chain 115 is driven by a driving member100. In this example, driving member 100 comprises a dual drive sprocketthat includes sprockets 114 a, 114 b. It will be appreciated thatdriving member 100 may comprise any suitable number of sprockets,including but not limited to a dual drive sprocket as shown in FIG. 13,a triple drive sprocket as shown in FIG. 14, or any other suitablenumber of sprockets. It will further be appreciated that driving membermay comprise any suitable size sprockets, including but not limited to afour tooth sprocket, five tooth sprocket, a six-tooth sprocket, an eighttooth sprocket, and various combinations thereof. Use of a dual drivesprocket, such as driving member 100 shown in FIG. 13, and acorresponding conveyor chain configured to be used with a dual drivesprocket, such as conveyor chains 25, 115, 205, may reduce operationalnoise and improve sprocket tooth life. The two sprockets 114 a, 114 bcomprising driving member 100 may be substantially identical to eachother and configured to rotate in unison with each other. By way ofexample only, in the embodiments shown in FIG. 13, sprockets 114 a, 114b are each eight-tooth sprockets.

As shown, sprockets 114 a, 114 b are spaced apart so that they arealigned with the side strap bosses 37, 38 and the vertical sprocketopenings 59 along each side of the chain 115. In the illustratedembodiment, as conveyor chain 115 wraps around driving member 100, eachsprocket tooth 112 engages a side strap boss 37, 38 or the base 56 of aflight arm 53, 54 via a vertical sprocket opening 59 along both sides ofthe chain 115. As shown, a first sprocket tooth 112 may abut a firstside strap boss 37, while a second sprocket tooth 112 may abut a secondside strap boss 38, while a third sprocket tooth 112 may be received byand extend at least partially through a vertical sprocket opening 59.Although not shown in FIG. 13, additional sprocket teeth may engageadditional side strap bosses and vertical sprocket openings as the chainwraps around the dual sprocket. In the illustrated embodiment, thesprocket teeth 112 do not directly engage or contact connecting pins 31,32) or flight pins 51, 52. Because the points of engagement betweenconveyor chain 115 and sprocket teeth 112 (i.e. side strap bosses 37, 38and flight arm bases 56) are thicker than the points of engagement insome prior art conveyor chains (where sprocket teeth directly engagebearing pins in the chain), conveyor chain 115 may provide improvedchain life and strength.

As shown in FIG. 14, conveyor chain 205 is driven by a driving member200. In this example, driving member 200 comprises a triple drivesprocket that includes two outer sprockets 214 a, 214 b and a centralsprocket 214 c. It will be appreciated that driving member 200 maycomprise any suitable number of sprockets, including but not limited toa dual drive sprocket as shown in FIG. 13, a triple drive sprocket asshown in FIG. 14, or any other suitable number of sprockets. It willfurther be appreciated that the driving member may comprise any suitablesize sprockets, including but not limited to a four tooth sprocket, fivetooth sprocket, a six-tooth sprocket, an eight tooth sprocket, andvarious combinations thereof. Use of a triple drive sprocket, such asdriving member 200 shown in FIG. 14, and a corresponding conveyor chainconfigured to be used with a triple drive sprocket, such as conveyorchains 25, 115, 205, may reduce operational noise and improve sprockettooth life. The two outer sprockets 214 a, 214 b may be substantiallyidentical to each other, while central sprocket 214 c may be configuredto have half as many sprocket teeth as outer sprockets 214 a, 214 b.Other suitable relationships between the outer sprockets and the centralsprocket may be apparent to those of ordinary skill in the art. Allthree sprockets 214 a, 214 b, 214 c may be configured to rotate inunison with each other. By way of example only, in the embodiment shownin FIG. 14, outer sprockets 214 a, 214 b are each eight-tooth sprocketsand central sprocket 214 c is a four-tooth sprocket.

As shown, outer sprockets 214 a, 214 b are spaced apart so that they arealigned with the side strap bosses 37, 38 and the vertical sprocketopenings 59 along each side of the chain 205. Also, in this example,central sprocket 214 c is positioned so that the teeth 112 of centralsprocket 214 c are received in the gap between adjacent universalconnector assemblies 40 and engage a universal connector assembly 40. Inthe illustrated embodiment, as conveyor chain 205 wraps around drivingmember 200, each sprocket tooth 112 of the outer sprockets 214 a, 214 bengages a side strap boss 37, 38 or the base 56 of a flight arm 53, 54via a vertical sprocket opening 59 along both sides of the chain 205. Atthe same time, each sprocket tooth 112 of central sprocket 214 c engagesa universal connector assembly 40 along the central longitudinal axis ofthe chain 205. The sprocket teeth of central sprocket 214 c engagegrooves 45, 47 formed in universal connector assembly 40. As shown, afirst sprocket tooth 112 of an outer sprocket 214 a, 214 b may abut afirst side strap boss 37, while a second sprocket tooth 112 of an outersprocket 214 a, 214 b may abut a second side strap boss 38, while athird tooth 112 of an outer sprocket 214 a, 214 b may be received by andextend at least partially through a vertical sprocket opening 59. At thesame time, a first sprocket tooth 112 of central sprocket 214 c may bereceived by and extend at least partially through an opening between afirst pair of adjacent universal connector assemblies 40, while a secondsprocket tooth 112 of central sprocket 214 c may be received by andextend at least partially through an opening between a second pair ofadjacent universal connector assemblies 40. Although not shown in FIG.14, additional sprocket teeth 112 on outer the outer sprockets 214 a,214 b may engage additional side strap bosses and vertical sprocketopenings and additional sprocket teeth 112 on central sprocket 214 c mayengage additional openings between additional pairs of adjacentuniversal connector assemblies 40 as the chain wraps around the drivingmember 200. In the illustrated embodiment, the sprocket teeth 112 do notdirectly engage or contact connecting pins 31, 32 or flight pins 51, 52.Because the points of engagement between conveyor chain 205 and sprocketteeth 112 (i.e. side strap bosses 37, 38, flight arm bases 56, anduniversal connector assemblies 40) are thicker than the points ofengagement in some prior art conveyor chains (such as chains wheresprocket teeth directly engage bearing pins in the chain), conveyorchain 205 may provide improved chain life and strength.

In an alternate embodiment (not shown), the driving member may comprisea single sprocket, such as central sprocket 214 c described above. Insuch an embodiment, the single sprocket may be positioned and configuredto engage the chain by having the teeth of the sprocket received betweenadjacent universal connector assemblies, similar to the central sprocket214 c described above.

FIG. 18 illustrates an alternative embodiment of the invention, whereina solid articulating connector 304 is utilized to replace some or all ofthe universal connector assemblies 40, along the length of the chain300. FIG. 24 illustrates another embodiment 302, wherein all of theuniversal connector assemblies 40 are replaced by the solid articulatingconnector 304. The articulating connector 304 is in the form of a solidsingle piece or body that is formed of an appropriate steel material,such as a carbon alloy steel. In the chains of FIGS. 18 and 24, likereference numerals will be utilized for those parts and portions of thechain previously discussed herein. Specifically, chains 300 and 302include a plurality of flight arm assemblies 50 connected with side linkassemblies 35, with appropriate connectors. In the embodimentillustrated in FIG. 18, every other universal connector is a singlepiece solid articulating connector 304 of the invention, along withother universal connector assemblies 40. As discussed herein, the chaincan be driven by a suitable drive mechanism 200, including either a dualsprocket arrangement, or a triple sprocket arrangement, for example (SeeFIG. 14).

Referring to FIGS. 18 and 19, universal connector 304 is coupled witheach of the respective side link assemblies and flight arm assemblies byrespective flight pins 51, 52, and connecting pins 31, 32. Theconnectors 304 are captured between the side straps 33, 34, and flightarms 53, 54. The pins pass through apertures 306, 308 formed in theconnector 304 to extend transversely, or from side to side in the body,as illustrated in FIGS. 20-22. The apertures 306, 308 extend laterallyor from side to side in the articulating connector, and are dimensionedwith respect to the diameter of the pins, and are configured so as toprovide movement and articulation of the pins within the connector, andthus, provide articulation of the chain 300, 302, as illustrated inFIGS. 18-20 and 24. In one embodiment, the apertures 306, 308 aredimensional in length L, with respect to the pin to be larger than thediameter D of a pin (31, 32, 51, 52) length so as to providearticulation in the path of chain movement. Generally, the heightdimension H will be similar to the pin diameter D, with some nominalclearance. In one exemplary embodiment, the length L may be up to threetimes (3×) diameter D in length, while the height may be around D with a+0.015 inch clearance or more.

Turning to FIGS. 21-23, unique solid articulating connector 304 of theinvention operates similar to a universal connector but provides greaterchain strength and eliminates the need for the more complicateduniversal connector assembly 40. As such, this eliminates the need foruniversal link 42, the connector link 43, as well as the variousuniversal pins 41. As such, the articulating connector 304 reduces thecomplexity of the chain, increases the chain strength and also reducespotential breakage points associated with a universal connectorassembly. Furthermore, the solid single piece articulating universalconnectors 304 weigh around 2-3 pounds less than a typical universalassembly 40, and thus, can significantly reduce the weight of the chainby, on average, 200 pounds, for a typical chain length. The articulatingconnector 304 is uniquely formed and shaped with specific curved andprofiled apertures and surfaces to provide the articulation anduniversal movement of the chains, as desired, and as necessary for theirproper operation. In one embodiment of the invention, the connector maybe configured to provide an articulation angle in the range from0°-150°.

Turning to FIGS. 21-23, the articulating connector 304 has a uniqueconfiguration and shape to provide the desired universal movement,articulation, and robustness of the solid articulating connector, inaccordance with the invention. The solid articulating connector isshaped so as to provide the desired articulation, as well as to allowthe necessary clearance around portions of the drive mechanism, such asa sprocket shaft and/or tail shaft roller, as discussed herein.Therefore, the invention provides a solid single piece articulatingconnector with a profile design to allow articulation of a conveyorchain on bulk material conveyor equipment. The solid articulatingconnector profile is dimensioned, and can be modified, within a range toallow essentially no articulation for straight running conveyors, or upto 150° total articulation for a single articulating connector around apin, such as pins 51, 52, and pins 31 and 32, as shown in FIGS. 18-20.

Turning to FIG. 21, a top cross-sectional view of a solid articulatingconnector 304 is illustrated, showing apertures 306, 308 therein at bothends of the connector. The apertures are in the form of uniquelyconfigured and profiled holes that will have a diameter D dimensionreflective of the size of the various flight pins, or connecting pinshandled by connector 304. The connector is dimensioned to have a blockheight H_(b) and a block width W_(b). Block height H_(b) may be in therange of a hole diameter plus 0.125 inches (hole D+0.125) to (3× holeD). The hole diameter D might be in the range of 0.25 inches-2.50inches. As such, a suitable block height H_(b) might be from 0.375inches-7.5 inches. In one embodiment, the H_(b)=2.25 inches. The widthW_(b) might be in the range of 1 inch-5 inches. In one embodiment, theW_(b)=2.25 inches.

Articulating connector 304 may be dimensioned to have a suitable pitch Pof 1 inch-10 inches. In one embodiment, the pitch P is around 3.63inches. The embodiments of the articulating connector 304 illustratedalso has a center section 310 having a certain material thickness. Thecenter section spans between the top and bottom walls 311, 313 of theconnector. The center section 310 might also be eliminated. The materialthickness of the center section 310 (Dimension C in FIG. 22) might beanywhere from 0 inches up to 9.75 inches, which would reflect an upperlimit of approximately the pitch P minus the hole diameter D. In oneembodiment, such thickness is around 0.75 inches. In the center section310, because of the radiused shape of holes of apertures 306, 308, thethickness will vary along the height of section 310. Furthermore, theconnector includes a wall thickness T that may be from approximately0.0625 inches up to 2.5 inches. This reflects a wall thickness T that isfrom 0.0625 inches up to one-half of the block height H minus the holediameter D ((block height H-hole diameter D)/2). In one embodiment, thethickness T=0.55 inches.

In accordance with one aspect of the solid articulating connector 304 ofthe invention, the side connector surfaces are appropriately curved andprofiled inwardly to provide the desired articulation, as well asoperation with the drive mechanism driving a chain. To that end, thesolid articulating connector 304 includes contoured profiles in thesides, top, and bottom of the connector. Referring to FIG. 21, the sides315, 317 of the connector have an exterior profile that is contouredwith an indent or inwardly profiled surface 312 that is dimensioned indepth D₁ and width W₁, on both sides of the connector. The inwardlyprofiled surfaces 312 provide a suitable articulation angle A, asillustrated in FIG. 20. The profiled surfaces 312 are configured toreceive a portion of the flight arm assembly or a portion of the sidelink assembly to provide articulation of the chain. More specifically,as illustrated in FIGS. 19 and 20, the profiled surfaces 312 areconfigured to receive an end portion 360 of side straps 33, 34, or toreceive an end portion 362 of a base 56 for providing articulation ofthe flight arm assembly and side link assembly with respect to eachother and articulation of the conveyor chain along its path of travel364, as shown in FIG. 19. The profiled surfaces 312 may be comprised ofsuitable angled or chamfered surfaces, or curved/radiused surfaces toallow proper articulation, the depth D₁ and the width W₁ and radius R₁provide the desired articulation, as shown in FIGS. 19 and 20. To thatend, in one embodiment of the invention, the depth D₁ might be anywherefrom 0 inches-2.5 inches, or from essentially 0 inches-one-half of blockwidth W_(b). As may be understood by a person of ordinary skill in theart, a profile surface 312 having a depth D₁ of 0 inches wouldessentially be a straight block, without a particular side profile. Thewidth W₁ might be anywhere from 0 inches-12.5 inches, or essentiallyfrom 0 inches to the dimension of the pitch plus the hole diameter(pitch P+hole D).

In one embodiment, the surface is dimensioned with D₁=0.25 inches,W₁=2.18 inches, and an R₁=2.50 inches. The edges 319 might form radiusedtransition edges at a radius of around 0.75 inches in one embodiment.Referring to FIG. 21, the overall block length L_(b) might be in therange of 1.25 inches-15 inches. Generally, the block length L_(b) mightbe in the range of 1 inches plus the hole diameter D₁, up to the pitch Pdimension plus the hole diameter D, plus two times the wall thickness T((pitch P+hole D+(2× wall thickness T)). In one embodiment, theL_(b)=5.88 inches.

Referring again to FIG. 21, solid articulating connector 304 includesopposing ends of the connector that include profiled end surfaces 316that work in tandem with the exterior side profiled surfaces 312 toprovide the articulation of connector 304. The profiled surfaces 316 maybe suitably chamfered, or may be outwardly radiused, or could be in theform of a sharp corner. In FIG. 21, a radiused edge or surface is shown,and may have a radius range of 0 inches (sharp corner) to 5 inches, orgenerally from 0-(wall thickness T+hole D). In one embodiment, theradius is around 0.25 inches. The profiled surfaces 316 engage a portionof either the side straps 33, 34, or the base 56, as shown in FIG. 19,when the chain articulates. As seen in FIG. 19, the profiled surfaces312 and profiled surfaces 316 are engaged on opposite sides of the chainduring articulation.

As seen in FIGS. 21 and 22, each of the holes or apertures 306, 308 isconfigured to receive one of the noted pins (31, 32, 51, 52) that couplethe connector to various side link assemblies or flight arm assemblies.In accordance with one aspect of the invention, each of the apertureopenings includes a pin hole profiled surface that forms a curved orradiused surface along an outer surface, as indicated by referencenumeral 320 in the figures, and along an inner surface 321. The profiledor curved surfaces 320, 321 of apertures 306, 308, allow a smootharticulation between each of the various pins, and the solidarticulating connector 304. The surfaces 320, 321 open up the holes 306and 308 to have a diameter that is equal to the hole size or larger. Thediameter D is reflective of the diameter of a pin 32, 51 in the solidarticulating connector 304 (See FIG. 20). Surfaces 320, 321 also followsa radiused profile that is sized based on the articulation angle that isdesired, such as from 0-150° articulation, as illustrated inarticulation angle A of FIG. 21. The profiled or curved surface 320allows the solid articulating connector to roll on the pin duringarticulation. In one embodiment, the profiled surfaces 320, 321 reflecta radius of around 1.25 inches. The ends of the solid articulatingconnector might also be appropriately chamfered at an angle A₂ of around5 degrees, or suitable draft angle. The profiled surfaces 320, whichwill bear most of the load from the pins 31, 32, 51, 52, may beinduction hardened to have a greater hardness. The surfaces 320 of theapertures 306, 308 are hardened at a specific depth around the aperturesto a greater hardness rating than the rest of the link. For example,while the articulating connector might have a hardness of around 40-44on the Rockwell C Scale (Rc), the surfaces 320 might be inductionhardened to have a hardness rating of around 50-54 Rc. In accordancewith one embodiment of the invention, the hardness may be induced to adepth D of ⅛ inch to 3/16 inches deep around the surfaces 320 andextending through the apertures from side to side.

Turning to FIG. 22, the connector 304 is profiled inwardly along the topand bottom surfaces in accordance with one aspect of the invention, toprovide clearance and articulation around the rollers of the drive shaftand tail shaft. For example, the top and bottom connector surfacesinclude inwardly profiled surfaces 323, 325 therein that allow clearanceand articulation around the sprocket foot shaft and/or tail shaftroller. As illustrated, the profiled surfaces are shown to have a depthof D₂, and a width of W₂ and a radius R₂, and may be comprised ofcooperative surfaces to form the profile, or curve, which will provide aclearance of the rollers, as the articulating connectors move over therollers. A suitable profile for the depth D₂ would be from 0 to 3.75inches, or roughly 0-one-half the block height H_(b). The widthdimension W₂ might be in the range of 0-12.5 inches, or from 0 to(pitch+hole diameter). As would be understood by a person of ordinaryskill in the art, if a depth and width of 0 inches would essentiallyrefer to a block that does not have the noted clearance profile, asillustrated in FIG. 22. Other embodiments would have the desirableangled chamfer or radius curves for providing the profile illustrated inFIG. 22 along the top and bottom of the connector 304. In oneembodiment, the profiled surface has D₂=0.25 inches, W₂=2.13 inches, andR₂=2.40 inches. Corner edge surfaces 327 have a radius of around 0.75inches.

The aperture diameter D might be in the range of 0.25-2.5 inches todefine the curved inner surfaces from top to bottom of apertures 306,308 to accommodate the pins. In one embodiment D=1.14 inches.

FIG. 23 illustrates an alternative embodiment of the invention, whereinthe exterior side surfaces 324 of the sides of the solid articulatingconnector on either end of the connector and either end profiledsurfaces 312 are also profiled. Specifically, surfaces 324 are chamferedor radiused to, or otherwise profiled outwardly from, the connectorsides to increase the effective block width W_(b). Specifically, asshown by solid articulating connector 304 a in FIG. 23, side surfaces324 are profiled with a suitable radius or chamfer to provide aneffective widening of the block width W_(b) outwardly from the ends ofsolid articulating connector 304 a. Generally, the top profile wouldthen more aptly resemble a “bow tie” shape, as illustrated in FIG. 23.For example, an 11° chamfer angle A_(c) might be provided on oppositeends of the point defining the widest W_(b). The chamfer works withradiused surfaces reflect by R₃ to form a W_(b)=2.44 in one embodiment.Connector 304 a may have aperture dimensions and profiling, as well astop and bottom dimensions shown in FIG. 22.

Referring to FIG. 20, providing a profiled, radiused, or chamferedsurface, and thus, a wider block width W_(b) at the surfaces 324, asillustrated in FIG. 23, will add additional material on the side, andthus, take up space or slack in between the various side straps and/orflight arms in the chain. As shown in FIGS. 19 and 20, when the chainarticulates, uniquely profiled openings 306 and 308, and the variousprofiled surfaces 312, 323, 325, 320, 321, 316 provide movement of thesolid articulating connector 304 around the pins 32 and 51. However,when the chain is straight, as shown in portions of FIG. 18, there maybe spacing between the opposing side straps or flight arms that providessome slack between the sides of the solid articulating connector 304 andthose components of the chain. By providing a profiled, radiused, orchamfered surface 324, as shown in FIG. 23, such slack may be addressed,while still providing suitable articulation of the link assemblies, withrespect to the solid articulating connector 304. The side profiledsurfaces 312 provide clearance to prevent interference with the flightsand the base or head 56 of the flights, as shown in FIG. 20. Profiledsurfaces 320, 321 provide smooth articulation between the pins and theconnector. Profiled surfaces 316 prevent interference between theconnector and opposing flight bases 56. The profiled surfaces 323, 325provide clearance around sprocket rollers.

FIG. 24 illustrates another embodiment of the chain, wherein the solidarticulating connectors 304 are utilized between each of the linkassemblies in the chain 302, rather than every other one, as illustratedin FIG. 18. Thus, FIG. 24 provides a chain that is even lighter, andwhich still maintains the ability to articulate as desired, similar tothe articulation provided by the universal connector assembly, asutilized in other embodiments. Thus, chain 24 eliminates any of thedrawbacks associated with the universal connector assemblies 40, byutilizing only the invented solid single-piece articulating connector304 of the invention.

FIGS. 25 and 26 illustrate additional embodiments of the invention. FIG.25 illustrates a solid articulating connector 304 b. The solidarticulating connector 304 b is somewhat similarly configured and shapedwith various profiled and contoured surfaces, as the articulatingconnector 304 is illustrated in FIGS. 20-22, for example, although itmight also be made to incorporate the design of connector 304 a asillustrated in FIG. 23. The solid articulating connector 304 b alsoincludes raised ribs 350 at the end of the articulating connector. Theraised ribs, on opposite sides of the connector, and along the top andbottom surface (partially) essentially form or define a grooved surfaceor groove 352 in each end of the connector. The ribs provide addedstrength at the ends of the articulating connector. The defined groove352 is configured for sprocket alignment, such as when a third sprocketis utilized to drive the chain.

Referring to FIG. 26, an embodiment of the chain is illustratedutilizing the solid articulating connector 304 b, as illustrated in FIG.25. The drive mechanism is a triple drive sprocket 200 that incorporatesthree sprockets. The outer sprockets and the teeth thereof engagesections of the flight arm assemblies 50 and side link assemblies 30, asshown. A center sprocket engages the chain at each of the solidarticulating connectors 304 b, as shown in FIG. 26. More specifically,as illustrated, the third sprocket or center sprocket has teeth whichengage the various grooves 352 of the solid articulating links 304 b.

In another embodiment of the invention, a chain design providessignificant noise reduction, while maintaining proper movement andspacing of the various links. In such an embodiment, as illustrated inFIG. 27, the various solid articulating connectors 304, 304 a, 304 b ofa chain, incorporate flexible spacers 350 on either side of the solidarticulating connector. More specifically, the spacers 350 arepositioned between an appropriate connector (e.g., 304, 304 a, 304 b)and the bases 56 of a flight arm in an assembly, or the side straps 33,34 of an assembly. As illustrated in FIG. 27, an exemplary embodimentincorporates a spacer 350 between the solid articulating connector andeach of the flight arm or side link assemblies. That is, the spacers arepositioned on each side of the articulating connects.

The flexible spacer 350 may be made of a suitably soft material forproviding flexibility and cushioning, such as urethane, to provide noisereduction between the solid articulating connector and the assembliesthat make up the links of the chain. Furthermore, the spacers provide asuitable distance or spacing between the solid articulating connectorand the various chain components so as to maintain a specific alignmentand spacing of the various links while the chain moves and articulates,and is driven by the sprockets. In one exemplary embodiment, the spacerwould generally be a circular or washer-type component. A center openingis formed therein for passage of flight pins or connecting pins, and hasan inner diameter of around 1.125 inches. The outer diameter might bearound 2 inches. Of course, other material or size embodiments might beutilized, in accordance with the invention, to maintain the desirednoise reduction and spacing. In one exemplary embodiment, the thicknessof the spacer 35 is around 0.094 inches. Of course, that dimension mightalso be varied, and still achieve the desired noise reduction andspacing of the invention.

FIG. 28 illustrates another alternative embodiment of the invention,wherein a solid articulating connector 404 is utilized to replace someor all of the universal connector assemblies 40, along the length of thechain 402. FIG. 28 illustrates an embodiment 402, where each universalassembly is replaced with connectors 404. As discussed above forconnector 304, the articulating connector 404 is in the form of a solidsingle piece or body that is formed of an appropriate steel material,such as a carbon alloy steel. In the chains of FIGS. 28, 32, and 33,like reference numerals will be utilized for those parts and portions ofthe chain previously discussed herein. Specifically, chain 402 includesa plurality of flight arm assemblies 50 connected with side linkassemblies 30, with appropriate connectors. In the embodimentillustrated in FIG. 28, each universal connector is a single piece solidarticulating connector 404 of the invention. As discussed herein, thechain can be driven by a suitable drive mechanism 200, including eithera dual sprocket arrangement, or a triple sprocket arrangement, forexample (See FIG. 14).

Referring to FIGS. 28 and 32, universal connector 404 is coupled witheach of the respective side link assemblies and flight arm assemblies byrespective flight pins 51, 52, and connecting pins 31, 32. Theconnectors 404 are captured between the side straps 33, 34, and flightarms 53, 54. The pins pass through apertures 406, 408 formed in theconnector 404, to extend transversely, or from side to side, in thesolid body, as illustrated in FIGS. 29-31. The apertures 406, 408 extendlaterally or from side to side in the articulating connector 404, andare dimensioned with respect to the diameter of the pins. The apertures406, 408 are configured so as to provide movement and articulation ofthe pins within the connector, and thus, provide articulation of thechain 402, as illustrated in FIGS. 28, 32 and 33. In one embodiment, theapertures 406, 408 are dimensioned in length L, with respect to the pinto be larger than the diameter D of a pin (31, 32, 51, 52) length so asto provide articulation in the path of chain movement (See FIG. 30).Generally, the height dimension H will be similar to the pin diameter D,with some nominal clearance. In one exemplary embodiment, the length Lmay be up to three times (3×) diameter D in length, while the height maybe around D with a+0.015 inch clearance or more.

Turning to FIGS. 29-31, unique solid articulating connector 404 of theinvention operates similar to a connector 304, and provides greaterchain strength and eliminates the need for the more complicateduniversal connector assembly 40. As such, the articulating connector 404also reduces the complexity of the chain, increases the chain strengthand also reduces potential breakage points associated with a universalconnector assembly. Furthermore, the solid single articulating universalconnectors 404 weigh around 2-3 pounds less than a typical universalassembly 40, and thus, can significantly reduce the weight of the chainby, on average, 200 pounds, for a typical chain length. The articulatingconnector 404 is also uniquely formed and shaped with specific curvedand profiled apertures and surfaces, as well as wing components and someflat surfaces, to provide the articulation and universal movement of thechains, as desired, and as necessary for their proper operation. In oneembodiment of the invention, the connector may be configured to providean articulation angle in the range from 0°-150°.

Turning to FIGS. 29-31, the articulating connector 404 has a uniqueconfiguration and shape to provide the desired universal movement,articulation, and robustness of the solid articulating connector, inaccordance with the invention. The solid articulating connector isshaped so as to provide the desired articulation, as well as to allowthe necessary clearance around portions of the drive mechanism, such asa sprocket shaft and/or tail shaft roller, as discussed herein.Furthermore, the connector 404 is shaped to reduce noise of the chain asit runs over the tail roller. Therefore, the invention provides a solidsingle piece articulating connector with a profile design to allowarticulation of a conveyor chain on bulk material conveyor equipment.The solid articulating connector profile is dimensioned, and can bemodified, within a range to allow essentially no articulation forstraight running conveyors, or up to 150° total articulation for asingle articulating connector around a pin, such as pins 51, 52, andpins 31 and 32, as shown in FIGS. 28, 32-33.

FIG. 29 is a perspective view of a solid articulating connector 404, inaccordance with one embodiment of the invention. Connector 404incorporates a solid body that incorporates top and bottom connectorsurfaces 423, 425 that have portions that are essentially flat, or areflattened, rather than contoured, as in the embodiment of connector 304.While most of the top and bottom surfaces are illustrated as flattened,there may still be portions of those surfaces that have some contours,such as portions, near the end of the connector body. Furthermore,connector 404 incorporates wing components, or wings 450, that extendfrom the connector 404, and form part of the top and bottom surfaces 423and 425. The wings 450 extend from both sides of the connector 404, atthe top and bottom surfaces 423, 425, as illustrated in FIG. 29. In theembodiment of FIG. 29, a pair or wings are positioned on the top of theconnector proximate to top surface 423, and a pair of wings is alsopositioned along the bottom of the connector proximate the bottomsurface 425. In an alternative embodiment of the invention, asillustrated in FIG. 29, the pair of wings 450 might only be positionedon one of the top or the bottom of the connector, and proximate a top orbottom surface. Portions of the surfaces 453 of the wings 450 might alsobe flattened similar to the flattened surfaces 423, 425 to formflattened top and bottom surfaces to the connector body. The wings arepositioned along the length L_(B) of the connector body, generally atthe middle of the connector body. Referring to FIG. 30, the wings mightbe positioned to coincide with the center section 410 of the connector.

In accordance with one aspect of the invention, the combination of thewings 450 and the flattened top and bottom surfaces 423 and 425 providea wider effective connector 404 at the top and bottom that does not haveprofiled top and bottom surfaces. The connector 404 contacts thesurfaces and rollers of the drive system for chain 402. The effectivelywider connector rides flat on various chain rollers, such as the tailroller, similar to the side straps 33, 34, and the flight arms 53, 54.In that way, as the overall chain progresses over a roller, such as thetail roller, the solid connector 404 does not sink onto the tail rollerlike a connector that has profiled top and bottom surfaces. That is, thewings 450 effectively widen the profile of the solid connector 404, andin combination with the flattened top and bottom surfaces 423, 425,provides a solid connector 404 that has a profile along the top andbottom surfaces closer to the top and bottom profile of a side strap ofthe conveyor chain. The solid connector 404 thus, prevents a change inthe profile or contour between the various side straps, flight arms, andsolid connectors 404, as the chain 402 moves over the rollers, and thus,prevents the chain from bouncing, or going up and down, as each of thevarious link elements of the chain pass over a roller. This, in turn,keeps the chain smoothly on the roller, and reduces the noise generatedas the chain passes over a roller.

Turning to FIGS. 30 and 31, a top cross-sectional view and side view ofa solid articulating connector 404 are illustrated, showing apertures406, 408 therein at both ends of the connector. The solid articulatingconnector 404 has similarities to connector 304 in construction, whichwill be described. The apertures are in the form of uniquely configuredand profiled holes that will have a diameter D dimension reflective ofthe size of the various flight pins, or connecting pins handled byconnector 404. The connector is dimensioned to have a block height H_(b)and a block width W_(b). Block height H_(b) may be in the range of ahole diameter plus 0.125 inches (hole D+0.125) to (3× hole D). The holediameter D might be in the range of 0.25 inches-2.50 inches. As such, asuitable block height H_(b) might be from 0.375 inches-7.5 inches. Inone embodiment, the H_(b) is around 2.25 inches. The width W_(b) mightbe in the range of 1 inch-5 inches. In one embodiment, the W_(b) isaround 2.25 inches.

Articulating connector 404 may be dimensioned to have a suitable pitch Pof 1 inch-10 inches. In one embodiment, the pitch P is around 3.50inches. The embodiment of the articulating connector 404 illustratedalso has a center section 410 having a certain material thickness. Thecenter section spans between the top and bottom walls 411, 413 of theconnector. The center section 410 might also be eliminated. The materialthickness of the center section 410 (Dimension C in FIG. 31) might beanywhere from 0 inches up to 9.75 inches, which would reflect an upperlimit of approximately the pitch P minus the hole diameter D. In oneembodiment, such thickness is around 0.75 inches. In the center section410, because of the radiused shape of holes of apertures 406, 408, thethickness will vary along the height of section 410. Furthermore, theconnector includes a wall thickness T that may be from approximately0.0625 inches up to 2.5 inches. This reflects a wall thickness T that isfrom 0.0625 inches up to one-half of the block height H minus the holediameter D ((block height H-hole diameter D)/2). In one embodiment, thethickness T is around 0.55 inches.

In accordance with one aspect of the solid articulating connector 404 ofthe invention, the side connector surfaces 412 between the wings 450 onthe top surface 423 and the wings on the bottom surface 425 areappropriately curved and profiled inwardly to provide the desiredarticulation, as well as operation with the drive mechanism driving thechain. To that end, the solid articulating connector 404 includescontoured profiles in the sides of the connector. Referring to FIG. 30,the sides 415, 417 of the connector have an exterior profile that iscontoured with an indent or inwardly profiled surface 412 at the centerof the connector between the wings 450 that is dimensioned in depth D₁and width W₁, on both sides of the connector and between an upper set ofwings and a lower set of wings. The inwardly profiled surfaces 412, incombination with the wings will provide a suitable articulation angle A,as illustrated in FIG. 33. The profiled surfaces 412 are configured toreceive a portion of the flight arm assembly when the chain bends or aportion of the side link assembly to provide articulation of the chain.More specifically, as illustrated in FIGS. 32 and 33, the profiledsurfaces 412 are configured to receive an end portion 460 of side straps33, 34, or to receive an end portion 462 of a base 56 for providingarticulation of the flight arm assembly and side link assembly withrespect to each other and articulation of the conveyor chain along itspath of travel 464, as shown in FIG. 32. The profiled surfaces 412 maybe comprised of suitable angled or chamfered surfaces, orcurved/radiused surfaces to allow proper articulation, the depth D₁ andthe width W₁ and radius R₁ provide the desired articulation, as shown inFIGS. 32 and 33. To that end, in one embodiment of the invention, thedepth D₁ might be anywhere from 0 inches-2.5 inches, or from essentially0 inches-one-half of block width W_(b). As may be understood by a personof ordinary skill in the art, a profile surface 412 having a depth D₁ of0 inches would essentially be a straight block, without a particularside profile. The width W₁ might be anywhere from 0 inches-12.5 inches,or essentially from 0 inches to the dimension of the pitch plus the holediameter (pitch P+hole D).

In one embodiment, the surface is dimensioned with D₁ of around 0.25inches, W₁ of around 1.5 inches, and an R₁ of around 3.00 inches. Theedges 419 of surface 412 might form radiused transition edges at aradius of around 0.75 inches in one embodiment. Referring to FIG. 30 theoverall block length L_(b) might be in the range of 1.25 inches-15inches. Generally, similar to connector 304 the block length L_(b) mightbe in the range of 1 inches plus the hole diameter D₁, up to the pitch Pdimension plus the hole diameter D, plus two times the wall thickness T((pitch P+hole D+(2× wall thickness T)). In one embodiment, the L_(b) isaround 5.827 inches.

Referring again to FIG. 30, solid articulating connector 404 includesopposing ends of the connector that include profiled end surfaces 416that work in tandem with the exterior side profiled surfaces 412 toprovide the articulation of connector 404. The profiled surfaces 416 maybe suitably chamfered, or may be outwardly radiused, or could be in theform of a sharp corner. In FIG. 30, a radiused edge or surface is shown,and may have a radius range of 0 inches (sharp corner) to 5 inches, orgenerally from 0-(wall thickness T+hole D). In one embodiment, theradius is around 0.25 inches. The profiled surfaces 416 engage a portionof either the side straps 33, 34, or the base 56, as shown in FIG. 32,when the chain articulates. As seen in FIG. 32, the profiled surfaces412 and profiled surfaces 416 are engaged on opposite sides of the chainduring articulation.

As seen in FIGS. 30 and 31, each of the holes or apertures 406, 408 isconfigured to receive one of the noted pins (31, 32, 51, 52) that couplethe connector to various side link assemblies or flight arm assemblies.In accordance with one aspect of the invention, each of the apertureopenings includes a pin hole profiled surface that forms a curved orradiused surface along an outer surface, as indicated by referencenumeral 420 in the figures, and along an inner surface 421. The profiledor curved surfaces 420, 421 of apertures 406, 408, allow a smootharticulation between each of the various pins, and the solidarticulating connector 404. The surfaces 420, 421 open up the holes 406and 408 to have a diameter that is equal to the hole size or larger. Thediameter D is reflective of the diameter of a pin 32, 51 in the solidarticulating connector 404 (See FIG. 31). Surfaces 420, 421 also followsa radiused profile that is sized based on the articulation angle that isdesired, such as from 0-150° articulation, as illustrated inarticulation angle A of FIG. 33. The profiled or curved surface 420allows the solid articulating connector to roll on the pin duringarticulation. In one embodiment, the profiled surfaces 420, 421 reflecta radius of around 1.25 inches. The ends 416 of the solid articulatingconnector might also be appropriately chamfered at an angle A₂ of around5 degrees, or suitable draft angle (See FIG. 30). The profiled surfaces420, which will bear most of the load from the pins 31, 32, 51, 52, maybe induction hardened to have a greater hardness. The surfaces 420 ofthe apertures 406, 408 are hardened at a specific depth around theapertures to a greater hardness rating than the rest of the link. Forexample, while the articulating connector might have a hardness ofaround 40-44 on the Rockwell C Scale (Rc), the surfaces 420 might beinduction hardened to have a hardness rating of around 50-54 Rc. Inaccordance with one embodiment of the invention, the hardness may beinduced to a depth D of ⅛ inch to 3/16 inches deep around the surfaces420 and extending through the apertures from side to side.

Turning to FIG. 31, the connector 404 has a generally flat (i.e.non-radiused) top and bottom surfaces that include the wings 450 inaccordance with one aspect of the invention, to provide smooth travelaround the tail roller.

Referring to FIG. 34, the wings 450 may provide an overall effectivewidth of the connector 404 W_(w) in the range of 1.0 to 6.0 inches. Inone embodiment, W_(w) might be around 3.5 inches. The wings may have athickness T_(w) in the range of 0.25 to 1.5 inches. In one embodiment,T_(w) is around 0.83 inches. Also, as illustrated in FIG. 34, the wings,while flat on the upper and lower surfaces 423, 425, may be angled withrespect to each other at the surfaces 460, in an angular range A_(w)from 0 degrees to 90 degrees. In one embodiment of the invention, A_(w)is around 10 degrees.

Referring to FIG. 35, the wings 450 may be formed to have an overalleffective width W_(w) in the range of 0 inches to L_(B)/3 inches. In oneembodiment, W_(w) is around 1.25 inches. The side surfaces 451 of thewings 450 might also be tapered in an angle with respect to each otherA_(s) in the range of 0 degrees to 150 degrees. The wings 450 cannot bemade too wide with respect to dimension W_(w) because articulation isnecessary between the various links, as illustrated in the FIGS. 32, 33.Generally, because the wings 450 are located at the top and bottomsurfaces 423, 425 of connector 404, and are kept somewhat thinner intheir overall side profile dimension T_(w) the end portions 460, 462 ofthe various links which engage connector 404 will pass somewhat underthe wings during articulation, as illustrated in FIGS. 32 and 33, tootherwise engage the profiled surfaces 412. However, there may be someengagement of the wings 450 with the end portions 460, 462 of each ofthe respective links that are coupled to connector 404.

FIG. 28 illustrates an embodiment of the chain, wherein the solidarticulating connectors 404 are utilized between each of the linkassemblies in the chain 402. However, similar to FIG. 18, the connectors404 might be used at every other universal connector position.

In another embodiment of the invention, a chain design providessignificant noise reduction, while maintaining proper movement andspacing of the various links, and, as shown in FIG. 27, the varioussolid articulating connectors may incorporate flexible spacers 350 oneither side of the solid articulating connector. Such spaces might alsobe used with the connectors 404 described herein.

The various conveyor chains disclosed herein may comprise an even pitchalong substantially the entire length of the conveyor chain, althoughthis is not required. The pitch may comprise the distance betweenadjacent connecting pins 31, 32 and flight pins 51, 52. In oneembodiment, the pitch may comprise about 3½ inches, although anysuitable pitch may be used depending on the particular application. Byway of example only, the pitch may also range from about 1 inch to about5 inches in length, or more particularly from about 2½ inches to about4½ inches in length. A conveyor chain with an even pitch may provide foran increased number of sprocket teeth engaged with the chain and mayallow for the use of a driving member that comprises two or moreindividual sprockets.

The present chain, as described and illustrated herein, provides aparticularly robust and wear resistant chain that improves upon thechain design provided by the flight assemblies and universal connectorassemblies. The inventive chain allows more sprocket engagement and thusprovides better inset chain flow over a foot shaft with more teethengaged to carry the chain load. Furthermore, the chain provides animproved and higher breaking strength. Because the dual sprockets drivein the flight arm attachment apertures and on the side strap bosses, thechain eliminates significant pin wear and failure caused from pinbreakage. Also, the solid articulating connectors provide increasedflight articulation in the movement of the chain. Still further, thechain provides noise reduction and maintains a desired spacing of thevarious links for proper operation.

It should be appreciated that the various components may be comprised ofany suitable material known in the art that exhibits the requisitestrength and durability characteristics based on the intendedapplication of the chain. By way of example only, the various componentsmay comprise forged steel, cast steel, spring steel, composite steel,plastic, other suitable materials and combinations thereof. Each of thecomponents may comprise the same material, or alternatively, differentcomponents may comprise different materials. In addition, by way ofexample only the flight arms 53, 54 or any other suitable components,may be made of composite steel and plastic, urethane, or other materialthat can reduce noise levels during operation, although this is notrequired.

Having shown and described various embodiments of the present invention,further adaptations of the methods and systems described herein may beaccomplished by appropriate modifications by one of ordinary skill inthe art without departing from the scope of the present invention.Several of such potential modifications have been mentioned, and otherswill be apparent to those skilled in the art. For instance, theexamples, embodiments, geometrics, materials, dimensions, ratios, steps,and the like discussed above are illustrative and are not required.Accordingly, the scope of the present invention should be considered interms of the following claims and is understood not to be limited to thedetails of structure and operation shown and described in thespecification and drawings.

What is claimed is:
 1. A conveyor chain comprising: a plurality of side link assemblies, at least one side link assembly including a pair of opposing side straps positioned on either side of the chain; a plurality of flight arm assemblies, at least one flight arm assembly including a pair of opposing flight arms positioned on either side of the chain; a plurality of articulating connectors, an articulating connector positioned between a flight arm assembly and a side link assembly to couple the assemblies together, the at least one articulating connector including: a solid piece for coupling the flight arm assembly and side link assembly together; side surfaces of the solid piece having profiled surfaces therein configured for receiving a portion of a side link assembly or a portion of a flight arm assembly for providing articulation in the chain; a pair of wings positioned proximate at least one of a top surface or a bottom surface of the solid piece, a wing of the pair extending to each side of the solid piece.
 2. The conveyor chain of claim 1 comprising a pair of wings positioned on each of the top surface and the bottom surface of the articulating connector solid piece, a wing from each pair extending to each side of the solid piece from the respective top or bottom surface.
 3. The conveyor chain of claim 1 wherein the surface where the pair of wings is positioned is flattened.
 4. The conveyor chain of claim 1 wherein a flight arm assembly includes a flight arm having an elongated body formed with and extending from an integral base, a vertical sprocket opening formed in the integral base to extend vertically through the integral base and being configured for engaging a tooth of a drive sprocket to drive the flight arm.
 5. The conveyor chain of claim 1 wherein a side link assembly includes a side strap having a base and at least a pair of side strap bosses extending outwardly from the base and configured to engage a tooth of a drive sprocket to drive the side strap.
 6. The conveyor chain of claim 1 further comprising at least one flight pin coupled between the opposing flight arms, the articulating connector including at least one aperture extending laterally in the solid piece that is configured to receive the flight pin for coupling the articulating connector with the flight arm assembly.
 7. The conveyor chain of claim 1 further comprising at least one connecting pin coupled between the opposing side straps, the articulating connector including at least one aperture extending laterally in the solid piece that is configured to receive the connecting pin for coupling the articulating connector with the side link assembly.
 8. The conveyor chain of claim 1 wherein the articulating connector includes at least one aperture extending laterally in the solid piece, the aperture configured to receive a pin for coupling the articulating connector with at least one of the flight arm assembly or the side link assembly, the aperture including at least one profiled surface to allow the articulating connector to rotate on the pin.
 9. The conveyor chain of claim 1 wherein the articulating connector has opposing ends, the opposing ends including profiled surfaces configured for engaging at least one of a portion of a side strap of a side link assembly or a portion of a base of a flight arm assembly for providing articulation of the flight arm assembly and side link assembly with respect to each other.
 10. The conveyor chain of claim 1 wherein the profiled surfaces of the side surfaces of the solid piece are configured for providing an articulation angle in the chain in the range of 1-150 degrees.
 11. A conveyor chain system comprising: a driving member, the driving member including a first drive sprocket and second drive sprocket, each of the first drive sprocket and the second drive sprocket having a plurality of teeth; a conveyor chain positioned between the drive sprockets for being driven by the drive sprockets of the driving member; the conveyor chain comprising: a plurality of side link assemblies, at least one side link assembly including a pair of opposing side straps positioned on either side of the chain, the side straps engaging a drive sprocket; a plurality of flight arm assemblies, at least one flight arm assembly including a pair of opposing flight arms positioned on either side of the chain, the flight arms engaging a drive sprocket; a plurality of articulating connectors, an articulating connector positioned between a flight arm assembly and a side link assembly to couple the assemblies together, the at least one articulating connector including: a solid piece for coupling the flight arm assembly and side link assembly together; side surfaces of the solid piece having profiled surfaces therein configured for receiving a portion of a side link assembly or a portion of a flight arm assembly for providing articulation in the chain; a pair of wings positioned proximate at least one of a top surface or a bottom surface of the solid piece, a wing of the pair extending to each side of the solid piece.
 12. The conveyor chain system of claim 11 comprising a pair of wings positioned proximate to each of the top surface and the bottom surface of the articulating connector solid piece, a wing from each pair extending to each side of the solid piece from the respective top or bottom surface.
 13. The conveyor chain of claim 11 wherein the surface where the pair of wings is positioned is flattened.
 14. The conveyor chain of claim 11 wherein a flight arm assembly includes a flight arm having an elongated body formed with and extending from an integral base, a vertical sprocket opening formed in the integral base to extend vertically through the integral base and being configured for engaging a tooth of a drive sprocket to drive the flight arm.
 15. The conveyor chain of claim 11 wherein a side link assembly includes a side strap having a base and at least a pair of side strap bosses extending outwardly from the base and configured to engage a tooth of a drive sprocket to drive the side strap.
 16. The conveyor chain of claim 11 wherein the articulating connector includes at least one aperture extending laterally in the solid piece, the aperture configured to receive a pin for coupling the articulating connector with at least one of the flight arm assembly or the side link assembly, the aperture including at least one profiled surface to allow the articulating connector to rotate on the pin.
 17. An articulating connector for use in a chain to connect link assemblies of the chain, the articulating connector comprising: a solid body having a top surface, a bottom surface and side surfaces; at least one aperture formed in the solid body and extending from side to side in the body; side surfaces of the solid body having profiled surfaces therein configured for receiving a portion of a link assembly of a chain for providing articulation in the chain; a pair of wings positioned proximate at least one of the top surface or the bottom surface of the solid body, a wing of the pair extending to each side of the solid body.
 18. The articulating connector of claim 17 further comprising a pair of wings positioned proximate to each of the top surface and the bottom surface of the articulating connector solid piece, a wing from each pair extending to each side of the solid piece from the respective top or bottom surface.
 19. The articulating connector of claim 17 further wherein portions of the wings and portions of at least one of the top and bottom surfaces are flattened.
 20. The articulating connector of claim 17 wherein the wings are positioned along the length of the connector body generally at the middle of the connector body. 